As more of our industry migrates towards electric forklifts, it is important to maintain your forklift batteries and chargers. Properly maintained forklift batteries and chargers will:

• Perform better on a daily basis by holding charges longer and maximizing output
• Last longer! By maintaining your batteries and chargers to manufacturer's recommendations, you ensure the longest life possible
• Be safer to work around. Poorly maintained batteries and chargers can present a danger to those working near or on them

This month we provide some tips to help you get the most out of your forklift's batteries and chargers.

Battery Maintenance Tips

1. Charge Properly

   • Only charge when the battery is between 20–30% capacity (don’t top off during shifts).

   • Always allow a full charge cycle—avoid interrupting mid-charge unless absolutely necessary.

2. Maintain Proper Water Levels

   • Check electrolyte levels weekly, and top off with distilled water after charging if needed.

   • Never overfill; it can cause overflow during charging.

3. Keep Batteries Clean

   • Regularly clean the battery case and terminals with a damp cloth or baking soda solution (neutralizes acid residue).

   • Corrosion or dirt buildup can lead to energy loss or safety hazards.

4. Equalize Charges

   • Perform an equalization charge (a longer charge to balance cell voltage) weekly or per manufacturer’s recommendation to prevent sulfation and extend life.

5. Inspect for Damage

   • Look for cracks, bulges, corrosion, or leaks.

   • Tag and remove damaged batteries from service immediately.

6. Monitor Temperature

   • Keep batteries in a cool, dry place. Overheating during charging can reduce battery lifespan.

   • Avoid exposing batteries to extreme temperatures (ideal range: 60–80°F).

Charger Maintenance Tips

1. Use the Correct Charger

   • Always use the manufacturer-recommended charger for the specific battery type and voltage.

2. Inspect Cables & Connectors

   • Check for frayed wires, loose connections, or melted plugs regularly.

   • Damaged connectors can cause poor charging or fire hazards.

3. Keep Chargers Clean & Ventilated

   • Ensure chargers are free of dust and debris and have proper airflow to avoid overheating.

4. Don’t “Opportunity Charge”

   • Charging during short breaks or lunch can shorten battery life unless the battery is designed for it (like lithium-ion models).

5. Log Charging Activity

   • Keep a charging log or use battery management software to track usage and detect early signs of trouble

Bonus Tip:

Training operators and technicians on proper battery handling and safety procedures is key to avoiding damage and extending battery and charger life.

Learn more about Training by AM Davis and visit our Forklift Batteries and Chargers page to learn more about our products. For a free consultation, please contact us at 804-233-0051.